1980 gsx250 project

[ukjules]

As for mig welding (with or without gas)
@ B bill - is it possible then (say on mower decks - for the non trained ?

Exhausts i agree are probably too much but mine is rusted so i might try on the back
box as i have nothing to lose.


IMG_0280.jpg

[Wallowgreen]

You can post more than one picture but not by importing the picture directly you have to use a hosting site like photobucket or imageshack then link to them. Info on how to do that if you're interested can be found at:

http://members.dslextreme.com/users/bikecliff/

on the left side of the page first link under the flashing icons around the "READ ME" link

[ukjules]

Think for future projects i need to teach myself mig wleding
and also perhaps one of those zinc plating kits ?

All removable parts now sprayed , primed, base and clear coated.
Used that epoxy paint which i think is brilliant.
looks excellent but the frame which i am not doing will show !

pics to follow and a possible start up movie before the weekend is out !

Electrics are going to stump me.
Ignition circuit ok but there are bodged bare wires around the battery which
is to do with the lights i am sure. might need some help ...

[ukjules]

Update.
This bike has almost cracked me several times.
I cant seem to understand why but the bodged terribly electrics may have something to
do with it - as i am useless at electrics but have to learn.

A good chap has sold me an exhaust and swinging arm . (When i learn how to weld i will
sort my other one out myself)
I actually went up for an airbox but came back with other things i needed more urgently.

Anyway started putting it back together as i simply must ride this thing before i go any further.
Remeber it was a wreck carried to my house on a trailer.

Jobs done:
Carbs stripped as it was running like a dog.
Incredibly not too many stripped bolts and a total dismantle and put back together
has made the bike sing ! So timing, valve clearances, Plugs, mixture, carb dismantle
me sorting out new earth wires has got the bike going well.

now it is electrics.

IMAG0526.jpg

[ukjules]

Calm yourselves calm yourselves ! I promised video and that it would go by the weekend !

http://vid1360.photobucket.com/albums/r659/rainstick2/first%20start%20up%20tuned_zpsow3p8ng8.mp4

Tomorrow will continue:

-Sprayed parts back on
-try and put a new seat cover on (have rubbed down and rust treated the seat pan)
-Balance the carbs (forgot that ) All other possible tuning done
-Test run

Still need (or want)
- A original seat
- A 2 into 2 exhaust

both of these are hard to find but it goes now and i can wait.
Also this bike was meant to be next winters project so i am a bit ahead but the frame does
need to be powder coated and loads more spraying.
I always have to get the bike tuned and mechanically ok before i do that though.

[ukjules]

Took it for a quick spin today of about 6 miles.
went fine. But hell is it slow ! have not driven a 250 for so long.
Great for cruising though.

Issues:
-Front brake wires - dont know where they go so fb does not work
do they go in the light somewhere ? (I have wiring diagrams but still cannot understand them)
(All other electrics now work, i wish i new how i made them work - more luck)

-Headlight switch on rhs now broke. Tried to glue the light on/off switch and it broke again
other elements of switch work
-Considering zinc plating some items and whether to do myself or find someone near me.
- overall state of electric wiring is terrible (but working)
wish i new more and how to renew bits
-spraying seat base
- need to put on a new seat cover


Needed:
original seat
2 into 2 (twin silencers) for bike

[ukjules]

First run out of bike

march 16 first run out.jpg

First run out with only the foam and no seat base.
Loads to do but it is getting there mechanically.

[ukjules]

Carbs balanced today and mixture changed to 1.5 out. (was 2)
Now runs like a dream and revs and idles freely.

2nd swinging arm and seat pan being sprayed today.
Wish i could weld as both my seat pans need welding. they are just saveable.
the foam is perfect.
Need an original type seat cover now or a seat !

-die nut - ordered to thread the seat posts
-rear brake switch ebayed , as other broke
-light switch on handlebar RHS ebayed as internals broke.

electrics still to sort - front brake switch not working and headlight.
I so wish i was better at electrics.

IMAG0530.jpg

[ukjules]

spraying parts today and finished the painting of the seat pan.
It is just usable and firm enough after rust treatment.
Half the securing hooks are rusted off so i have tested spray glue.

I have a cover but for a different model that i will squeeze on for now until i
find a good seat cover.
I will post a picture of the abomination i have created tomorrow.

Swinging arm 3 coats of primer and now 3 coats of base coat. will clearcoat it tomorrow.
then I have a like new swinging arm.

Exhaust:
I realise that if i want a old style 2 into 2 exhaust i am going to have to get one made
especially.
this I will consider in stainless steel. It wil cost and as of yet i know no one who can do it
anywhere.
If anyone knows a exhaust maker let me know ! I simply must have the two into 2 look
and sound. A 2 - 1 on a 250 is ridiculous and sounds awful. Needs to be silent.

Electrics:
I am going to have to ask for help on this.
I am stuck , have problems seeing colours and find electrics impossible.
All i need is the front brake light to work and the headlight !
(Then i need someone to look at the wiring to see the mess i have made to make this happen.)



IMG_0290.jpg

[cloudbreakmd]

Looking good.

[1948man]

Good work for sure.

[ukjules]

It is now finally ready for an MOT to legally drive on the road.
(Pic of second swinging arm sprayed up and clear coated - came out very well)
Ill swap the one on bike with rust hole in it soon. considering welding it myself and buying a welder ...

I had an issue of it suddenly misfiring and stripped down the carbs ..... again, binned the old fuel (I hadn't done that)
and found one spark plug was coincidentally not firing.

All sorted now and is mechanically sound. (slow though !)
I suppose in 1981 when i was driving these things it seemed fast ?
Desperately need a 2 into 2 exhaust as these 2 into 1's dont work on small 250's i find.
I think that is why it is slow.

Going to have to treat the inside of the tank as slightly rusty and need to spray
the outside of tank.
I found the Suzuki colour code - 05k and the colour is "marble Canadian blue".
( Halfords cannot match this colour unfortunately so need to look elsewhere)
Need to find this spray paint !

some mechanical tuning stats for those people that like this :

- Valves all set within limits
- normal air box - with made to measure foam filter
- Mixture screw 1.75 out
- Cy compression test
Cy1 Cy2
Dry 210 195
Wet 225 (Dont know as forgot to put in the oil )

[ukjules]

Pic shows my bodged attempt at putting a seat cover for a 250 Katana gsx .... thing
onto my one. It works but is awful and when i find a new seat or a correct
looking seat cover I will refit it.
Still need to weld up the seat pan.

Now it is mechanically sound in every way , now the work starts to get it
to as it was.

Needed:
2 into 2 exhaust
Seat
Some side panels would not go amiss too.

Question:
The side panels should have black stripes.
Are these striped paint or decal ? Some of the black that is left
on my side panels look like a decal - but might be thick paint.
Need to know to know how to take it off ..... and the expense







Ready for MOT.jpg

[steveb922]

Decals.

http://www.cmsnl.com/suzuki-gsx400e-1980-t_model13616/partslist/FIG-61.html#results

[ukjules]

Nut die:
I bought a m6 nut die to thread the side of seat trip holding posts (as they were totally inaccessible).
they were 6.25mm approx and the nut die worked a treat.
All secure now and the seat can be easily dismantled when i find a
seat cover and to weld the seat pan.



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